CdTe solar cells were fabricated by depositing a Au/Cu contact with Cu
thickness in the range of 50 to 150 Angstrom on polycrystalline CdTe/
CdS/SnO2/glass structures. The increase in Cu thickness improves ohmic
contact and reduces series resistance (R(s)), but the excess Cu tends
to diffuse into CdTe and lower shunt resistance (R(sh)) and cell perf
ormance. Light I-V and secondary ion mass spectroscopy (SIMS) measurem
ents were performed to understand the correlations between the Cu cont
act thickness, the extent of Cu incorporation in the CdTe cells, and i
ts impact on the cell performance. The CdTe/CdS/SnO2/glass, CdTe/CdS/G
aAs, and CdTe/GaAs structures were prepared in an attempt to achieve C
dTe films with different degrees of crystallinity and grain size. A la
rge grain polycrystalline CdTe thin film solar cell was obtained for t
he first time by selective etching the GaAs substrate coupled with the
film transfer onto a glass substrate. SIMS measurement showed that po
or crystallinity and smaller grain size of the CdTe film promotes Cu d
iffusion and decreases the cell performance. Therefore, grain boundari
es are the main conduits for Cu migration and larger CdTe grain size o
r alternate method of contact formation can mitigate the adverse effec
t of Cu and improve the cell performance.